Non Ferrous Alloys-UNDERGRAD

8/18/2019 Non Ferrous Alloys-UNDERGRAD

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Metals and Alloy- IIDr. Indika De Silva

Senior LecturerDept. of Materials Science &

EngineeringUniversity of Moratuwa

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An alloy not intentionally contain iron

!roperties of non ferrous alloys

not availa"le in ferrous#

• $esistance to corrosion

• Ease of fa"rication % low meltingpoints

• ig' electrical and t'er(al

conductivity• Lig't weig't• Strengt' at elevated te(peratures

• high ductility wit' low yield points)*


3/80

Copper and Copper alloys• +opper ores are nor(ally associated wit' sulp'ur in w'ic'

copper can "e e,tracted fro( c'alcocite +u*S c'alcopyrite

+u-eS* and cuprite +u*.• +opper is an industrial (etal and widely used in unalloyed and

alloyed conditions% second ranked fro( steel and alu(inu(.

• Used (ostly in "uilding constructions and as electronic andelectrical products.

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General properties andcharacteristics

• Ductile metal ) 'ig'ly close packed 0111planes in -++ crystal structure

• excellent electrical conductivity %cloud of

free electrons is unifor(ly availa"le• Excellent thermal conductivity

• Good resistance to corrosion

• Good machinability

• Can be soldered bra!ed and welded• Ease of forming alloys with other

elements li"e #n $n Al %b $i &i etc'

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Applications of copper• Only second to silver for electrical conductance

Copper trolley wires

Electronic productsCopper finish parts Electronic products

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Copper: working behind the scenes in automotive applications

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Approximate Cost Per Unit olume for !rought "etals and Alloys

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Cast alloys- alloy t'at is poured as a li6uid intoa (old and cooled into a solid s'ape# ingot

(rought alloys ) cast alloy is sub*ected to+- forming process li"e rolling forging etc'- heat treatments

• +asted copper alloys 'ave 'ig' tensile andco(pressive strengt' good wear 6ualities.

• 'ardening e7ects of cold working can easily "ere(oved% recrystalli8ation te(perature less t'an*499+.

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widely used alloys are,

• Copper- #inc Alloys .rass/

• Copper- 0in Alloys .ron!e/

• Copper-&ic"el Alloys

• 1igh $trength Copper ).eryllium Alloys

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Copper- #inc Alloys .rass/

!'ase Diagra( of t'e +opper%


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Percentage compositionConstituent just below

the freezing point

Constituent after slow

cooling to 400°CCopper Zinc

100 to 67. 0 to !". α α

67. to 6! !". to !7 α % β α

6! to 61 !7 to !# β α % β#

61 to . !# to 4. β α % β#

. to 0 4. to 0 β β#

0 to 4!. 0 to 6. β β# % γ

4!. to 41 6. to # β % γ β# % γ

formation of a series ofsolid solutions

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0ensile strength increases wit'


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$hoc" resistance rises in α phase.

• falls considera"ly wit' a(ount of β.

• e,tre(ely brittle w'en γ is present.

1ardness rises in β phase.

Alloys containing only α phase suita"lefor cold wor"ing'

•α 4 β , 'ot working.• γ, avoided for any (ec'anical treat(ent

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Microstructure of α brasses

Annealing twins

• Annealing twins can be observed in the & grains when the alloy

has been cold worked and followed by annealing'

• A pair of grains is said to be twinned when the arrangement of

atoms in one of the grains can be generated from the other(during recrystallization) by reflection across a common

plane'

(win plane or boundary 12


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• (he twin$boundaries tend to be flat and the twin as a whole

will have a facetted appearance'

• Annealing twins observed in the & grains increases with the

)n contents'

Commercial bron*e

+,-.Cu$/-.)n0 Cartridge brass

+1-.Cu$2-.)n013


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• 3n cubic close$packed metals such as copper4 the ma5or part

of the twin interface is parallel to 6///7 planes which have

the stacking se8uence ''A9CA9C'''' (he stacking se8uenceof the 6///7 planes on the other side of the twin boundary is

a mirror refelction4 so that the se8uence across the

boundary is '''A9CA9AC9A''''

:tacking faults by themselves are simple two$dimensional defects' (hey carry a

certain stacking fault energy g; very roughly around a few /-- m'

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C 56777 - 8ed .rass 9: Cu ;: #n/

• >etter corrosion resistance % not suscepti"le to

stress corrosion cracking• used for orna(ents and for c'eap ?ewellery .

• @it'stand cold%work and cutting.

C 5


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@roug't +artridge "rass

Nominal Composition:

Cu ?@'$1/'

)n >@'2@$2/'2@4

Pb -'-14

Be -'-1:


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C 59777 - Munt! Metal 7 #n/

• 'e structure in room temp' is (i,ture of α ? β.

• %roportion may be controlled to so(e e,tent "yt'e rate of cooling. % % $apid cooling will suppresst'e for(ation of alp'a p'ase

Cast structure shows dendrites of

alpha +dark0 in a matrix of beta +white0

ot rolled "unt* metal sheet structure of

beta phase +dark0 and alpha phase +light01;


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Munt! Metal 7 #n/

Air cooled fro( t'e all β region at :*39+.

(idmanstatten structure % dendrites of D p'ase surrounded "y α precipitates.

α appears inside t'e D grains and on t'e D grain "oundaries.

α appears as long fat needles in a D (atri,.

much less α if t'is speci(en 'ad "een 2uenched.

more and @rounder@ α if slowly cooled

200X

*9

α

phase

D phase


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Applications )

• replace(ent for copper s'eat'ing placed

on t'e "otto( of "oats % anti%foulinga"ilities of t'e pure copper can "e(aintained cost e7ectively

% as it cost around two t'irds of t'epure copper

• arc'itectural work

• for valve ste( and condenser tu"es

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.ra!ing solder :7 Cu, :7 #n/

• consists of homogeneous β solution

in roo( te(p.•γ increases in a(ount as t'ete(perature falls rapidly. it ma"es

weld *oint harder'

**

C d ll d d


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Copper-ead alloys eadedbrasses/

• Leaded "rasses 'as S(all a(ounts of %b 7':-

6'7B/ w'ic' are added to (any types of "rassesto improve their machinability'

• Essentially pure lead B;;.;;C!" will "e distri"utedinter%dendritically in t'e copper as small

globules.• +old defor(ation (akes elongated !" glo"ules.

Bree$cutting brass extruded rod showing elongated

lead globules with the remained & phase

*/


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0in .rasses

• Increasing Sn contents gives a lighter

coloured (icrostructure of FG (ulti%p'ase.

"icrostructure of cast and hot rolled tin

brass'

+Cu ,'-$?>'-4 )n 2?'1$-'-4 :n -'$/'-4

Pb -'>-4 Be -'/-0

3ncreasing :n content gives a

microstructure of & phase +yellow0 in D

matrix +dark0

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•;B of $n addition in cartridge "rass i(prove

corrosion resistance in sea water.•7'7>B arsenic addition could al(osteli(inate de8inciHcation Bcorrosion condition.

•$eplacing Sn wit' Al gives "rass a self-

healing protective oxide on its surface.+alled Aluminum brasses

% corrosion resistance used for (arinecondensers.

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um num ron!e


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um num ron!e;7Al:&i:3e/

β phase breaks down to α and appa in cooling through ,--C to 1--C'

Fappa phase begins to precipitate as coarse particles at about ,--'

Fappa $ lamellar form4

$ variable composition containing Al4 Be4 Gi and "n'

α$ needle like structure4 make dark matrix'

Bormation of fine kappa within the α phase' *4

α phase

kappa coarse

particles

D phase


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!ree cutting brass: "#$%Cu& '%$% n & 'b

•9est machinability plus good mechanical and corrosion resistance

properties'

•Used for automatic high speed screw machine parts

Na*al brass: "0Cu & '+$2% n & 0$,%-n

• Also known as (O93G bron*e has increased resistance to salt

water corrosion'

•Used for condenser plates4 welding rods4 propeller shafts4 pistonrods and valve stems'

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Copper- 0in Alloys .ron!e/

!'ase Diagra( of t'e +opper%in Alloys*:


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Percentage compositionConstituent 5ust below

the free*ing point

Constituent after slow

cooling to --HCCopper (in

/-- to @1 - to /2 & &

@1 to @? /2 to / & % D &

@? to 1@ / to >> & % D & % I

,. to ,/ 22 to 2" β1(α β) α 3

formation of a series ofsolid solutions

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• solution is t'e softest it can "e rolled.

• and constituents do not e,ist in roo(te(perature.

• successive c'anges occurring at :9


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• A"sorption of o,ygen during solidiHcation in casting

results in $nH5 ma"e it brittle' • % is added as deo,idi8ing agent to i(prove casta"ility.

• @roug't +u%Sn "ron8es contain a"out 1.*3%19C Sn wit'up to 9.1C ! 'ence usually called p'osp'or "ron8es.

• 0winning is a c'aracteristic feature of t'e cold%workedand annealed alloy ) defect.

• ig' Sn BJ19C i(prove strengt' ) unworka"le "ut can"e casting.

Copper& tin bronzes

"icrostructure of phosphor bron*e

,>.Cu $@.:n$trace P4 showing recrystallised &

grains with annealing twins

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4in bronze• @$/-. :n >$. )n4 remaining copper'• Pressure castings4 bushings and bearings

5eaded tin bronze• ?$@'. :n4 .)n44 -'$/'. Pb 4 remaining copper'• Can be used upto - -B'•Pressure castings4 bushings4 electrical castings4 gears 4

pumps etc

6ig7 leaded tin bronze:• $/-.:n4 /$2.)n44 1$/.Pb

•9earings operating at high speeds and high pressure and forcorrosion resistant pumps'

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8un metal

• $/-. :n4 >$. )n4 remainder copper'

• Originally used for guns

• Jood tensile strength and resistance to corrosion'

• Used for bearings4 steam pipe fittings4 marine castings4

hydraulic valves and gears'

9:,;: Copper-0in Alloy

• Used for bearings and bells'• Sand castings ) slow cooling % 4 hard

structure'

•!ressure die castings ) rapid cooling % 4 less harder'

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Cu-;7 $n>%b

• As cast4 dendritic microstructure

• yellowish$white 3 p7ase can be seen'

• 9lack areasK shrinkage cavities or lead particles$

• each dendrite arm is copper$rich and etc7es more slo9ly

than the outside of each dendrite arm'$ inner potion is not

seen clearly'

200X%0X

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Copper-&ic"el Alloys

• +u and Ki are "ot' -++ and can for( solid

solution t'roug'out.

• Microstructure consists of phase- solidbinary system e,'i"its co(plete solidsolu"ility.

• &i ;7 57 67B/ are added to Cu to for(solid solution alloys called cupronic"el'

• Ki addition i(proves strengt' o,idation and

corrosion resistance.

• Ki greatly increases electrical resistivity of +uE,#::BCu->:B&i used for wire%woundresistance for electrical instru(ent.

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"icrostructure of cupronickel

1-.Cu$2-.Gi

consisting of recrystallised

& grain with twin bands

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General Applications• %ipe wor" in chemical plants

• Automotive Applications L E,tra surface protection is not re6uired

L e(ployed for "rake 'ydraulic suspension syste(sand cooling syste(s

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• Marine Applications L good resistance to biofouling - undesira"le

accu(ulation of (icroorganis(s plants and algae onwetted structures.

L resistance to sea water corrosion. L cladding for s'ips 'ulls fouling legs of oil rig platfor(s

and sea water intake screens.

• coins medals

% 'e copper wit' *3C nickel wit' 9.93%9.2C(anganese .

• 0hermocouplescopper->:B nic"el alloy develops a high and uniform

EM3 w'en coupled wit' ot'er (etals suc' as copper andiron.

• 8esistance (irecopper with >:B nic"el alloy is used for resistance wirein 'ig' precision resistors.

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l ll


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Cu-Al AlloysAluminum .ron!es/

• Al for(s solid solution in +u B p'ase up to;.2C at 343o+.

Annealed microstructure of

Cu$.Al4showing & grains

with twin bands'

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• Alu(iniu( "ron8es 'ave high strengthexcellent corrosion and good resistance towear and fatigue'

• Self%'ealing surface Hl( of Alu(iniu( o,ide %e,cellent corrosion resistance.

• 0ensile strength increases wit' increasing phase w'ile ductility drops o7.

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1igh $trength Copper ) .eryllium Alloys

• up to a"out * wtC produce dra(atic e7ects inseveral "ase (etals.

• In Cu-&i alloys .e addition pro(otesstrengt'ening t'roug' precipitation hardening.

• In Al alloys s(all addition i(proves o,idationresistance casta"ility and worka"ility.

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Applications

• Electronic components % electronic connectors

'ig' strengt' for(a"ility and favora"le elastic(odulus.

• Electrical e2uipment % switc' and relay "lades.

fatigue strengt' conductivity and stressrela,ation resistance.

• 8esistance welding systems )

'ot 'ardness and conductivity are i(portant

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$uperalloy

Excellent mechanical strength'

• ig' te(perature strengt' t'roug'solid solution strengthening'

• %recipitation strengthening ) +ar"ides.

Creep resistance at high temperatures'

Good surface stability'

Corrosion and oxidation resistance'

%!rotective o,ide layer BAl*/ +r*/

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$%picall% ha&e a matri' with an Austenitic face- centered

cubic cr%stal structure.

(ase allo%ing elements are usuall% Ni ) Fe and Ni an* Co.

Applications are in,

• Aerospace

• Industrial gas tur"ine• Marine tur"ine industry

ur"ine "lades for 'ot sections of ?et Engines% &i basesuper alloys'

• Su"(arines

• Kuclear reactors

• Military electric (otors

• +'e(ical processing vessels and 'eat e,c'anger tu"ing.

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Types of Superalloys

1astelloy

!redo(inant alloying ingredient is &i'

t'er alloying ingredients %

Mo Cr Co 3e Mn 0i #r Al C'

!ri(ary functions

• E7ective survival under 'ig'%te(perature.• ig'%stress service in severely corrosive

enviorn(ent.

• !ressure vessels of so(e nuclear reactorsc'e(ical reactors and pipes and valves.

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C iti f i h t ll


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Composition of various hastelloys

Alloy Co Cr Mo ( 3e $i Mn C &iHther

s

>%* 1 1 *: ) * 9.1 1 9.91>alanc

e)

>%/ / 1.3 *:.3 / 1.3 9.1 / 9.9143

(in.

Al%9.3

i%9.*

+%2 * 14 14 ) / 9.9: 1 9.91>alanc

e i%9.5

+%*999 * */ 14 ) / 9.9: ) 9.91>alanc

e

+u%1.4

+%** *.3 ** 1/ / / 9.9: 9.3 9.91>alanc

e

N%

9./3

+%*54 *.3 14 14 2 3 9.9: 1 9.91>alanc

eN%9./3

O%/9 * /9 3.3 *.3 13 1 1.3 9.9/ >alance

K"%

9.:

+u%*

K 9.* 5 14 9.3 3 1 9.: 9.9:>alanc

e

AlFi%

9.3

+u%

9./3>alanc

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Inconel

Austenitic nickel%c'ro(iu(%"asedsuperalloys.

Inconel alloys are typically used in hightemperature applications'

+o((on trade na(es for Inconel include#

Inconel 4*3

+'ronin 4*3

Alte(p 4*3

aynes 4*3

Kickelvac 4*3

Kicrofer 49*9.2:


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Inconel

Element (% by mass

Ni Cr Fe !o Nb Co !n Cu Al Ti Si C

"## $ &'-&$ "- & #. #. #.&

" ) #-* )- *-' & #. #.' #.' #. #.&

$&) # &$-& balance .)-*.* '.-. & #.* #.-#.) #." #.* #.* #.#)

ifferent ;nconels 7a*e 9idely *arying compositions

2;


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%roperties

Inconel alloys are oxidation and corrosion

resistant (aterials suited for extremeenvironments.

@'en 'eated forms a thic" stable

passivating oxide layer protecting t'esurface fro( furt'er attack.

$etains strengt' over a wide te(perature

range attractive for high temperatureapplications

w'ere alu(inu( and steel would succu(" tocreep.

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ig' te(perature strengt' isdeveloped "y

• $olid solution strengthening or

• %recipitation strengthening

- S(all a(ounts of K" co("ine wit'Ki to for( t'e inter(etallic co(pound&i6&b t'at for(s s(all cu"ic crystals

inhibit slip and creep eectivelyat elevated temperatures'

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!ac+inin

Inconel is a diPcult (etal to s'ape and (ac'ine dueto rapid work 'ardening.

age-hardened Inconels =;9/ are (ac'inedusing an aggressive "ut slow cut wit' a 'ard tool

(ini(i8ing t'e nu("er of passes re6uired. +utting of plate is often done wit' a water%?et

cutter.

Internal t'reads can "e cut "y single point(et'od on lat'e.

Kew w'isker reinforced cera(ic cutters are alsoused to (ac'ine nickel alloys.

3*


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Applications - encountered in extremeenvironments

• Oas tur"ine "lades seals co("ustors tur"oc'argerrotors and seals

• !u(p (otor s'afts 'ig' te(perature fastenersc'e(ical processing and pressure vessels 'eate,c'anger tu"ing.

• E,tensively used in "oilers of waste incinerators.

3/


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Extensively used Inconel alloys

• Inconel


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(aspaloy

Age 'ardening Ki%"ased superalloy.

Use in gas tur"ines.

0ypical Composition

• Kickel 3:C• +'ro(iu( 1;C

• +o"alt 1/C

• Moly"denu( 2C• itaniu( /C

• Alu(iniu( 1.2C

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%roperties

• Excellent strength up to =


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8efractory metals andAlloys

0ungsten and 0ungsten Alloys

0ungsten carbide (C/%hysical properties• 'ig' (elting !t *:59 =+

• e,tre(ely 'ard BNickers ardness nu("er R**2*

• Low electrical resistivity B1.5)*.*19T5 '((

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$tructure 'ere are two for(s of @+

• e,agonal for( -(C

• +u"ic 'ig' te(perature for( -(C

w'ic' 'as t'e rock salt structure.

-C) +oc, -alt -tructure α&


59/80

Applications

Machine tools• -or (aterials suc' as car"on or stainless steel

• In situations w'ere ot'er tools would wear away.

• +ar"ide generally produces a "etter Hnis' on t'epart and allows faster (ac'ining.

• +ar"ide tools can also wit'stand 'ig'er

te(peratures t'an standard 'ig' speed steeltools

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Military

• used in armor-piercing ammunition

• E7ective neutron reKector ) used intonuclear c'ain reactions for weapons.

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Domestic

• Used for rotating ball in the tips of

ballpoint pens to disperse ink during writing.• Lewellery% 'e Hnis' is 'ig'ly resistant to

scratc'es.

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0ungsten-0hH5 Alloys

'e @%'* alloy contains a dispersed secondphase of ; to 5B thorium'

'e t'oriu( dispersion en'ances thermo ionicelectron emission w'ic' in turn improves the

starting characteristics of gas tungsten arcwelding electrodes.

It also increases t'e ePciency of electron disc'argetu"es.

Imparts creep strength to wire at te(peraturesa"ove 1299 FC

4*


63/80

0ungsten 1eavy-Metal Alloys (1As/

ypically contain J7- J9 wtB ('

Most co((ercial @As are two-phase structures#

• !rincipal p'ase "eing nearly pure w.

• "inder p'ase containing t'e transition metals plusdissolved ('

Main properties are high density and high elastic stiness'

Applications

• Da(ping weig'ts for co(puter disk drive 'eads

• >alancing weig'ts for 'elicopter rotors and for guided(issiles

4/

&i bi ? &i bi ll


64/80

&iobium ? &iobium alloys

• Its cryogenic ductility and ease of fabrication are

e,cellent superior to t'ose of Mo and @.

• Ductile and soft (etal at elevated temperatures.

• $trength can be improved by alloying to (ake it

co(petitive wit' (oly"denu( alloys.

• ac" of oxidation resistance is a (a?or "arrier inusing structural applications at elevatedte(peratures.

• =:B of all &b (etal % minor alloying additions inlow-alloy steel'

• 57 to 5:B - additions in nic"el-base super alloysand heat-resisting steels'

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M l bd ? M l bd ll


65/80

Molybdenum ? Molybdenum alloys• utstanding electrical and thermal-conducting

capabilities and relatively high tensile strength.

• 0hermal conductivity is appro,i(ately 39C 'ig'ert'an steel iron or nickel alloys.

• Its electrical conductivity is t'e 'ig'est of allrefractory (etals a"out B1V/ t'at of copper.

• 'e (a?or use% alloying agent for

alloy tool steels

stainless steelsnic"el-base or cobalt-base super-alloys

to increase 'ot strengt' toug'ness and corrosionresistance.

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In t'e electrical and electronic industries


66/80

In t'e electrical and electronic industries

• used in cat'odes

• $adar devices

• (agnetron end 'ats

• (andrels for winding tungsten Hla(ents.

I(portant in t'e missile industry high-temperature structural parts B(a,i(u(1439=+ suc' as

• no88les

• leading edges of control surfaces• support vanes

• 'eal%radiation s'ields tur"ine w'eels and pu(ps.

44

TZM All (Tit i Zi i


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TZM Alloy (Titanium, Zirconium,Molybdenum)

Moly"denu(Ws pri(e alloy is


68/80

• -ailure of t'e "ase (etal as a result offracturing along grain boundaries'

•


69/80

4;

A h M t l


70/80

Amorphous MetalMetallic (aterial wit' a disordered ato(ic%

scale structure.

Crystalline atomic structure >morp7ous atomic structure

59


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Applications


72/80

Applications

Nitreloy >;'5B #r ;6'9B 0i ;5':B Cu ;7B &i

and 55':B .e/• ensile strengt' al(ost twice t'at of 'ig'%grade

titaniu(.

0i>7Cu6#r;7 %• / ti(es stronger t'an titaniu(

• Elastic (odulus nearly (atc'es "ones.

• 'e alloy does not undergo s'rinkage on solidiHcation.

Mg


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&ic"el based Alloys

Main properties

Hutstanding strength B2:9%1159 M!a

Corrosion resistance %particularly at 'ig' te(p.

can be forged and hot wor"ed DiPcult tocast.

@elding operations can "e perfor(ed wit' littlediPculty.

5/

Applicaions


74/80

Applicaions

+'e(ical & food processing industries

% Excellent corrosion resistance.

8esistant to salt water sulfuric acid highvelocity and high temperature steam'

Stea( tur"ine "lades.

Aircraft gas tur"ines

Excellent appearance si(ilar to t'at ofstainless steel.

L rna(entals 'ouse 'old ware.

52

Monel #+opper F 45C nickelF so(e iron


75/80

Monel #+opper F 45C nickelF so(e iron

$esistant to corrosion and acids

can wit'stand a re in pure oxygen typically (uc' more expensive t'an stainless

steel.

'ig'er 6uality musical instruments suc' as

tru(pets tu"as and frenc' 'orn rotors. used for "itchen sin"s and in the frames of

eyeglasses

53

0hree types of Monel


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0hree types of Monel

O-Monel+ 6B Al

% %recipitation hardened to a tensilestrengt' of 1199%1*29 M!a.

1-Monel+ 6B $i $- Monel+ >B $i

% >ot' are used for casting applications

andcan also "e precipitation 'ardened.

54

&ichrome


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&ichrome

&i-Cr alloy 97B &i 57B Cr/

% electrical resistors and 'eatingele(ents.

&i-Cr alloy


78/80

$hape Memory Alloys

Metallic (aterials t'at de(onstrate t'e ability to

return to their previously dened shape w'ensu"?ected to t'e appropriate 'eating sc'edule.

'e (ost e7ective and widely used alloys

% &i0i :7&i-:70i/

- CuAl&i

- Cu#nAl

Applications

% $o"otics% Oeneral Electric Aircraft Engines

% ydraulic -ittings Bfor Airplanes

% il line pipes for industrial applications

5:


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$ome corrosion-resistant in the &i-Cr


80/80

$ome corrosion resistant in the &i Crsystem

Alloy

Documents

Non Ferrous Alloys-UNDERGRAD